Pile weather stripping insertion and staking tool

ABSTRACT

A rotatable wheeled tool for simultaneously inserting and staking a weatherstrip into a slot, said tool comprising a body having a channel extending longitudinally from a first end to a second end, said channel configured to accommodate a length of weatherstrip through the body having sides extending a distance beyond the second end to form two legs and a rotatable wheel having an inserting edge and a staking edge, and mounted axially between said the legs with both the inserting and staking edges extending beyond the legs.

FIELD OF THE INVENTION

The present invention relates generally to weatherstrips, and moreparticularly, to the insertion of pile weatherstrips, and improved toolsand methods for inserting and staking pile weatherstrips into slottedstructures.

BACKGROUND OF THE INVENTION

Weatherstrips, particularly pile weatherstrips incorporating animpermeable barrier film or fin within the pile material, have excellentweathering properties. While such weatherstrips are used in variousplaces for various sealing purposes, they are particularly suitable forsealing or weatherstripping the small clearance openings betweenadjacent wood, aluminum or vinyl materials such as, for example,building materials. Such weatherstrips are particularly useful in doorpanels or window panels, or between the panels and the frames in whichthey are mounted, or between the door edge and an adjacent surface suchas a floor.

Today, plastics and vinyl materials are increasingly being used asbuilding materials such as, for example, window and door treatments andcasings. Vinyl casings are often manufactured by extruding long,continuous lengths which can be cut to length for customized jobs, orcut at regular intervals to make windows and door casings of standarddimensions. Typically, the vinyl lengths are extruded to specifications,and have slots throughout their length ("T-slots" also referred to as"C-slots") into which weatherstrips, preferably pile weatherstrips, areinserted. The pile strip is often backed with a flexible plastic stripserving as the pile base. The configuration of the pile strip can bemade to adapt to a slot of any shape. Therefore, for a T-slot, the pilestrip is configured into a dimensionally matching T-shape. It is thisT-shaped pile weatherstrip which must be inserted into the T-slot of awindow or door casing.

Pile weatherstrip insertion has been accomplished in many ways. Pilestrips have been pushed or pulled into the T-slot. The strips have alsobeen forced into the T-slots by applying a thin-wheeled roller over thestrip which is positioned over the slot. The slotted piece beingextruded is then moved forward relative to the roller to drive the stripinto the slot. See U.S. Pat. Nos. 5,103,547 and 4,528,736.

To secure the newly slotted strips in the T-slot, the strips areanchored into the slot by compressing sections of the lip of the T-slotagainst the base of the pile strip. This process is known as staking. Astaking wheel is provided at a separate staking station fartherdownline. The staking wheel is positioned adjacent the slot rim to crimpor pin the T-slot edge into the pile strip. U.S. Pat. No. 3,295,195shows a device which first inserts and later stakes pile weatherstripinto an aluminum extrusion.

Vinyl extruded window lengths are produced faster and more economicallythan aluminum counterparts. It would be convenient and economicallydesirable to insert pile weatherstrip into vinyl window lengths as partof the vinyl extrusion process. Such a process would eliminate the needfor a secondary pile strip insertion process into the T-slots. However,practical problems persist.

If the pile strip is inserted on the extruding line without locking in,or staking the pile strip, it will shift within the T-slot duringsubsequent cutting, handling and shipping. Strips that are not stakedrisk "drawback" or "shrink-back" after cutting. This refers to thecondition weatherstrip no longer extends to provide complete coverageover the entire length of the extruded, slotted material, but "drawsback" due to being stretched at the cutting stage due to weak or nostaking.

To properly stake the weatherstrip into place, a staking station must beput in place downline from the insertion station. Setting up both aninsertion station and a staking station on a vinyl extrusion line isdifficult to achieve without adversely affecting the vinyl extrusionrate and product yield. A tool that can accomplish such insertion andstaking on the extrusion line without interfering with vinyl extrusionrates would be highly advantageous.

SUMMARY OF THE INVENTION

The present invention provides a tool for inserting and staking aweatherstrip into a slot, for example the T-slot, of extruded materials.The tool has a body having a channel extending longitudinally from afirst input end to a second output end. The channel is configured toaccommodate and pass a length of weatherstrip through the tool body. Thetool body has sides extending a distance beyond the second end to formtwo spaced legs. The tool further has a rotatable wheel having incombination, both an inserting edge and a staking edge. The wheel ismounted axially between the two legs. Both the inserting and stakingedges of the wheel extend beyond said legs.

The present invention further provides a wheel for inserting and stakinga weatherstrip into a slot. The wheel comprises both an inserting edgeand a staking edge.

The present invention further provides a machine for inserting andstaking a weatherstrip into a slotted weatherstrip receiving piece. Themachine comprises an extruder for extruding a slotted length of materialalong a path, a hugger roll assembly, and a weatherstrip tool insertionand staking station comprising a tool positioned adjacent the path forreceiving weatherstrip to be inserted into the slotted material. Thetool further comprises a body having a channel extending longitudinallyfrom a first input end to a second output end, with the channelconfigured to accept a length of weatherstrip at the first input end andpass the length of weatherstrip through the body to the second outputend. The body has sides extending a distance beyond the second outputend to form two spaced legs. A rotatable wheel is having an insertingedge and a staking edge is positioned between the legs. The wheel ispositioned such that its circumference extends beyond the legs of thetool body.

Still further, the present invention provides a method forsimultaneously inserting and staking a weatherstrip into a slot. Asupply of slotted material is provided along with a supply ofweatherstrip to a tool. The tool has a body having a channel extendinglongitudinally from a first input end to a second output end. Thechannel is configured to accommodate and pass a length of weatherstripthrough the body. The body has sides extending a distance beyond thesecond end to form two legs. A rotatable wheel is rotatably positionedbetween the two legs. The wheel has an inserting edge and a stakingedge. The circumference of the wheel extends beyond said legs. A supplyof weatherstrip is then directed through the tool channel to therotatable wheel. The rotatable wheel and weatherstrip are locatedadjacent the slotted material. The wheel contacts both the weatherstripand the slotted material and simultaneously inserts and stakes theweatherstrip into the slot.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the first side of the tool.

FIG. 1a is a side view showing reciprocating staker feature.

FIG. 2 is an overhead view of the tool.

FIG. 3 is a view of the weatherstrip output end of the tool.

FIG. 3a is an output end view showing reciprocating staker feature.

FIG. 4 is a side view of the second side of the tool.

FIG. 5 is an underside view of the tool.

FIG. 5a is an underside view showing reciprocating staker feature.

FIG. 6 is a view of the weatherstrip input end of the tool.

FIG. 6a is an input end view showing reciprocating staker feature.

FIG. 7 is a perspective side view of the tool in operation.

FIG. 7a is a perspective side view of a staked extruded material withoutthe strip in place.

FIG. 8 is a view of the output end of the tool in operation.

FIG. 9 is a perspective elevated view of the tool in operation.

FIG. 10 is an axial view of an alternate embodiment of a staking wheel.

FIGS. 10a-10d show radial views of insertion/staking wheel of FIG. 10.

FIG. 11 shows an axial view of further embodiment of insertion/stakingwheel.

FIGS. 11a shows a radial view of the insertion/staking wheel of FIG. 11.

FIG. 12 is a schematic representation of a machine incorporating thetool.

FIG. 12a is a further schematic representation of a machine showingreciprocating staker feature.

DETAILED DESCRIPTION OF THE INVENTION

One preferred embodiment of the present invention is shown in FIGS. 1-6.The preferred tool 10 has a weatherstrip input end 12 and an output end14. Input end 12 has a channel 16 bored through the tool body andextending therethrough to the second end 14. Two legs 18, 20 extend pastthe output end 14 and are spaced apart a desired distance. A rotatablewheel 22 is positioned between legs 18, 20. The wheel 22 has aninserting edge 24 located about its outer first circumference. As shownin FIG. 1, wheel 22 also has a star-like area 28 with a plurality ofprojections 30. The outermost edges of the projections 30 form a secondcircumference of the "star." The second circumference of the wheel 22comprising projections 30 is referred to as staking wheel edge, orstaking edge 26. The top of tool 10 has adjustable set screws 32, 34.Additional set screws 36, 38 are positioned within the underside of thetool body 10, as shown in FIG. 5. Adjustment of the four set screwsaffects the vertical placement of wheel 22 between legs 18, 20, andaffects the distance the wheel circumference may extend below the bottomof the legs. The vertical positioning of wheel 22 and the wheel hub 40can be viewed through hub guide 42 in the side of legs 18, 20. Screwholes 44 are machined into the tool for joining the tool to a machinewhich can position the tool as desired. Spacing washer 23 is positionedbetween wheel 22 and leg 20.

FIG. 5 shows detailed features of a preferred embodiment of theunderside of tool 10 to be positioned adjacent the slotted material 60.The channel 16 through tool 10 emerges at narrow opening 70 via fastener71. Feeder guide 72 is securely positioned relative to opening 70. Toolpositioning guide 73 engages the extruded slotted material 60,preferably nesting adjacent T-slot 64, and positions the tool 10 in adesired orientation relative to the slotted material 60. In operation,the feeder guide 72 orients the emerging weatherstrip 62 in apredetermined orientation proximate the slotted material and the wheel22 to assist in proper weatherstrip insertion into the slot 64.

FIG. 6 shows the input end 12 of the tool 10 with channel opening 16.

FIGS. 7-9 show perspective views of tool 10 adjacent a slotted material60 that is to receive a segment of pile weatherstrip 62 into its T-slot64. FIG. 7 shows the pile strip 62 in position, inserted and staked intoslot 64 of slotted material 60. Tool 10 receives a length of, preferablycontinuous pile weatherstrip 62. The weatherstrip 62 has a base 68 andenters the tool 10 at first input end 12 at channel 16, and emerges fromthe second output end 14 of tool 10 directly over slot 64 of slottedmaterial 60. As slotted material 60 is passed under the stationary tool10 in the direction of arrow A relative to the tool, weatherstrip 62first encounters inserting edge 24 of wheel 22 which exerts a downwardforce on the weatherstrip 62, forcing the base 68 of the strip intoT-slot 64. As the wheel 22 rotates, and if sufficient force is present,projections 30 comprising the staking wheel surface 26 engage the slotedge, or rim 66 and deform or crimp the edge downward against the pilebase 68, holding or pinning the pile weatherstrip 62 in position withinthe slot 64.

FIG. 7a shows a segment of extruded slotted material 60 which has beenstaked by the wheel of the present invention. Stake marks 61 are moreeasily seen in this view where the pile strip has been removed forillustrative purposes only.

FIGs. 1a, 3a, 5a and 6a show an alternate embodiment of the presentinvention. In this embodiment, the wheel 22 is primarily responsibleonly for the inserting function. Reciprocating staking element 21 whichextends vertically from the tool body intermittently stakes the rim ofthe weatherstrip. It is understood that the reciprocating stakingelement is attached to gear mechanisms machined within the tool body. Inoperation, it is contemplated that the rotational motion of theinsertion wheel will provide, through a series of interconnecting gears,sufficient torque and force to drive the reciprocating staking elementinto the slotted material rim to adequately stake the pileweatherstripping as desired.

FIG. 8 shows a view of the output end 14 of tool 10. The wheel 22 exertsa force on weatherstrip 62 into slot 64 of slotted material 60.Inserting edge 24 and staking edge 26 of wheel 22 are clearly visible.Feeder guide 72 (not shown) presents the strip to the rotatable wheel ata selected angle and assists wheel 22 in orienting weatherstrip intoT-slot 64. Slot rim 66 is shown crimped, or staked against pile stripbase 68, securing the strip 62 into position within T-slot 64.

FIG. 10 shows an alternate embodiment of the present invention. Wheel 50has staking wheel projections 51 comprising projection edges 53 and aninsertion edge 52. In this embodiment, the outermost edges of thestar-like projections occur at the outermost radius and comprise thestaking edge. In operation, this wheel is positioned between legs 18, 20of tool 10.

FIG. 10a shows a radial view of the wheel of FIG. 10. The stakingprojection 51 comprising projection edges 53 clearly extends beyondinsertion edge 52. The projection staking edges as shown are blunt, orare presented at an angle of about 180° across the width of the edge.

FIG. 10b shows a preferred embodiment of the present invention whereinthe wheel 50 viewed radially shows the staking projection edge 53, ofthe projection 51 being angled in the axial direction. The preferreddegree of angle is from about 10° to about 80°, preferably from about20° to about 70°, and is most preferably about 30°.

FIG. 10c shows another embodiment of the present invention. In thisradial view of wheel 50, the staking projection edge 53 of theprojection 51 angled at about 120°. It is therefore contemplated thatthe edge of the staking edge projections of the staking wheel can beangled at any degree in either the axial or radial (not shown) directionof from 1° to about 180°, depending only upon the desired aggressivenessof staking to be accomplished, and taking into consideration theextruded material being staked. For vinyl extrusions, it has beenexperimentally determined that staking is achieved at angles of fromabout 0° to about 180° preferably from about 10° to about 80° and fromabout 100° to about 170°, with angles of about 30° and about 120° beingparticularly preferred.

FIG. 10d shows a further alternate embodiment of the present invention.Wheel 50 comprises an inserting edge 52 and a staking edge 51 having anangled outer edge 53. In this embodiment, the staking edge is acontinuous edge in contrast to the intermittent staking edge formed bythe plurality of intermittently spaced projections shown in FIGS. 10-10cand 11-11a. In this embodiment, the inserting and staking surfaces areboth wheels which may be machined out of one piece, or are separate andaffixed together, or are separate but placed proximate to one another,etc.

FIG. 11 shows another preferred embodiment of the present invention withthe wheel 80 viewed axially. FIG. 11a shows a radial view of the wheelof FIG. 11. Here, the staking edge formed by the outer edge ofprojections 82 is coincident with the inserting edge 81. In other words,the outermost circumferences of the projection edges of the stakingwheel and the insertion edge of the inserting wheel are about equal.

FIG. 12 shows a machine 90 for inserting and staking weatherstrip into aslotted extruded material. Weatherstrip 62 is fed from a continuous roll91 to first input end 12 of tool 10. Slotted material 60 is suppliedfrom extruder 92 and pulled from the extruder past staking/insertingstation 99 via hugger roll assembly 94 which frictionally engages theextruded material 60 and provides a specific and regulated pulling forceon the extruded slotted material 60.

In operation, the extruded slotted material is directed to a hugger rollassembly which grips the material and, through frictional force, drawsthe material from the extruder at a specified rate past the stationarystaking/inserting station 99. The tool 10 is held stationary by thedownward force applied to tool 10 by tension screws 95 through clamp 96supported by stand 97. The downward force is applied to the tool suchthat the wheel of the tool exerts a predetermined amount of pressure onthe slotted extruded material. The pressure can be varied by adjustingthe tension screws 95 of clamp 96 upward or downward. The wheel 50 oftool 10 engages weatherstrip 62 as it passes through channel 16 of tool10, the tool applying force to the strip 62 sufficient to insert thestrip into the slot 64 of slotted extruded material 60, whilesimultaneously staking the strip 62 in the slot 64 by deforming the slotrim 66 against the strip 62 and its base 68 to form stake marks 61.

FIG. 12a is a schematic representation of an alternate embodiment of thepresent invention, showing a machine similar to that already describedand shown in FIG. 12, except that reciprocating staking element 101attached to drive gears within housing 100 is responsible for thestaking function. The wheel of tool 10 remains responsible for insertingthe pile weatherstrip into the T-slot of the slotted extruded material.As the extruded material advances to the hugger roll assembly, in thisembodiment, the staking element reciprocates intermittently; alternatelyrising from and descending into the rim of the slotted material. Thestaking frequency may be set as desired, as would be readily understoodby one skilled in the field of reciprocating machine technology. In thisway, the pile strip is inserted and staked simultaneously at one stationalong the extrusion line. Such an embodiment may be particularly usefulfor extrusion materials that are especially difficult to stake.

It is understood that the combination inserting/staking wheel of thepresent invention may be adjustably raised or lowered between the legsof the tool of the present invention, as desired, via adjusting the setscrews provided. In operation, the tool engages the slotted material byresting immediately adjacent the slotted material such that the distanceof the wheel extending past the bottom of the legs is sufficient topush, or insert the pile weatherstrip into the T-slot. The wheels usedwith the tool may be adjustably raised, if desired, so that only theinserting edge of the wheel will impact the weatherstrip, and insert theweatherstrip into the slot. However, by setting the wheel lower, so thata greater amount of wheel is visible beneath the legs, and/or increasingpressure on the tool against the slotted material, the staking edge ofthe wheel will impact the edge or rim of the T-groove immediately afterthe pile has been inserted into the T-slot. See FIG. 7. In this way, thestrip will be simultaneously inserted by the inserting edge of thewheel, and staked by the staking edge of the wheel into the T-slot.

The lateral position of the wheel is also adjustable by use of one ormore spacing washers 23 on one or both sides of the wheel 22. Thislateral adjustability is a unique feature and especially useful, makingthe insertion/staking wheel assembly adaptable for use with T-slottedmaterials having varying wall thicknesses, thus requiring variedpositioning of the inserting/staking wheel.

If it is desired to lightly stake the strip (non-permanently) into theslot, the wheel can be so adjusted. If a firm, permanent staking isdesired, the wheel may be adjusted to descend lower such that a greateramount of the staking wheel edge will impact and crimp the rim or lip ofthe T-slot against the pile weatherstrip, thus firmly staking the stripinto the slot. Such non-permanent staking is often desirable to afford amanufacturer the opportunity to recycle extruded material. Beforerecycling can occur, pile stripping must be removed from the extrusion.

In an alternate embodiment of the present invention shown in FIGS.10-10c, a tool may use a wheel 50 that has a plurality of projections 51intermittently oriented about the circumference such that the combinedsurface of the projections form the staking edge. In this embodiment,the staking edge 53 of the wheel 50 would impact the strip and T-slotfirst; the pile strip simultaneously being inserted and staked with thesame wheel surface. The inserting wheel may still impact the pile stripand assist in the strip's proper seating in the T-slot. This wheel wouldbe especially useful when permanent strip staking is desired, but couldalso be adjusted when only inserting, or inserting and lightly stakingthe strip is desired.

Therefore, it is understood that combination wheels may be constructedwhere the staking edge circumference extends past the inserting edgecircumference, the inserting edge circumference extends past the stakingedge circumference, or the staking and inserting edges are coincident,depending only upon the desired end result. One or both of the insertingand staking edges may be angled if desired. One or both of the wheelsmay have continuous outer circumferences, or may have intermittentprojections. Further, the wheel of the present invention has beendescribed as one wheel having multiple edges or surfaces machined intothe wheel. It is to be understood that separate, multiple wheels may beheld in close association or affixed together. In this way the insertingand staking edges would occur on different but juxtaposed wheels.

Still further, the channel that extends through the tool may also rotatewithin the tool to achieve an angular path altering effect on the strip.In this way, the strip may be presented to the wheel at a specifiedangle, different or the same as the angle it entered the tool at thechannel opening.

The present invention further contemplates a tool for simultaneouslyinserting and staking a weatherstrip into a slot wherein a rotatablewheel or other inserting guide or plate contacts the weatherstrip andinserts the strip into a slot while a staking means simultaneouslystakes the strip into the slot. The staking means may be a reciprocatingpunch, a staking plate applying a constant force to the slot rim so asto crimp the rim, or any other means of crimping the extruded slotmaterial rim so as to stake the strip in place within the slot intemporary, semi-permanent, or permanent fashion as desired.

Temporary staking is understood to mean staking the pile strip into theslot so lightly that the strip may be removed from the slot with minimalforce applied to the strip. Semi-permanent staking requires significantforce to remove the strip from the slot, but the strip and slottedextruded material may be salvaged or recycled. Permanent staking isunderstood to mean that the strip cannot be removed from the slotwithout destroying either or both of the extruded material and/or thestrip.

The pattern of projections on the staking wheel is not critical. Thestaking wheel projections may be of any desired configuration, withblunt, rounded, pointed or angled, etc. ends. The staking wheel edge andinserting edge may also be one continuous surface or may beintermittent, such as by having a plurality of regularly or irregularlyspaced projections. If multiple wheels are desired, it is contemplatedthat one or both wheels may be rotatable or fixed in position.

In the most preferred embodiment, the tool is not self-driven; i.e. nomotorization within the tool is responsible for rotating theinsertion/staking wheel. However, the combined effect of the pressureexerted on the stationary tool by the clamp, and the frictional force ofthe wheel against the moving extruded slotted material results in thewheel's rotation. It has been found that the staking and smoothrotational wheel movement is facilitated when more than one stakingwheel projection contacts the extruded material at all times.

Many other modifications and variations of the present invention arepossible to the skilled practitioner in the field in light of theteachings herein. It is therefore understood that, within the scope ofthe claims, the present invention can be practiced other than as hereinspecifically described.

What is claimed is:
 1. A tool for inserting and staking a weatherstripinto a slotted material comprising:a body having a channel extendinglongitudinally from a first end to a second end, said channel configuredto accommodate and pass a length of weatherstrip through the body, saidbody having sides extending a distance beyond the second end to form twolegs; and a rotatable wheel having an inserting surface having aninserting edge as its periphery and a staking surface having a stakingedge as its periphery, said wheel mounted axially between said two legs,the staking surface abutting and immovable with respect to the insertingsurface; the staking edge defining a continuous periphery with aplurality of intermittent projections spaced apart by inner sections ofthe staking edge, the inner sections lying within an outer circumferenceof the inserting edge.
 2. The tool according to claim 1, wherein thetool simultaneously inserts and stakes the weatherstrip into the slot.3. The tool according to claim 1, wherein the inserting edge and stakingedge extend beyond said legs.
 4. The tool according to claim 1, furthercomprising a feeder guide to provide the weatherstrip to the rotatablewheel at a selected angle.
 5. The tool according to claim 1, wherein thechannel directs a length of weatherstrip to the rotatable wheel.
 6. Thetool according to claim 1, wherein the channel alters the path of theweatherstrip to provide the weatherstrip to the rotatable wheel at aselected angle.
 7. The tool according to claim 1, wherein the positionof the rotatable wheel is adjustable.
 8. The tool according to claim 1,wherein more than one projection contacts the slotted material at anytime.
 9. The tool according to claim 1, wherein the inserting edgeextends beyond the staking edge.
 10. The tool according to claim 1,wherein the projections of the staking edge extend beyond the insertingedge.
 11. The tool according to claim 1, wherein the inserting edge andthe projections of the staking edge have coincident circumferences. 12.The tool according to claim 1, further comprising multiple rotatablewheels.
 13. The tool according to claim 1 wherein the plurality ofprojections are generally rectangularly shaped.
 14. The tool accordingto claim 1 wherein the staking edge is angled in an axial direction ofthe wheel in one of a range of 10° to 80° and a range of 100° to 170°.15. A wheel for inserting and staking a weatherstrip into a slottedmaterial comprising a substantially planar inserting surface having aninserting edge as its periphery and a substantially planar stakingsurface having a staking edge as its periphery, the staking surfaceabutting and immovable with respect to the inserting surface, thestaking edge defining a continuous periphery with a plurality ofintermittent projections spaced apart by inner sections of the stakingedge, the inner sections lying within an outer circumference of theinserting edge.
 16. The wheel according to claim 15, wherein theinserting edge and staking edge simultaneously engage the weatherstrip.17. The wheel according to claim 15, wherein more than one projectioncontacts the slotted material at any time.
 18. The wheel according toclaim 15, wherein the inserting edge extends beyond the staking edge.19. The wheel according to claim 15, wherein the projections of thestaking edge extend beyond the inserting edge.
 20. The wheel accordingto claim 15, wherein the inserting edge and the projections of thestaking edge have coincident circumferences.
 21. The tool according toclaim 15 wherein the plurality of projections are generallyrectangularly shaped.
 22. The tool according to claim 15 wherein thestaking edge is angled in an axial direction of the wheel in one of arange of 10° to 80° and a range of 100° to 170°.